Method for producing carbon black



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J. J JAKOSKY ET AL METHOD FOR PRODUCING CARBON BLACK Original Filed March 31., 1933 1939- J. J. JAKOSKY ET Al. 2,143,355

METHOD FOR PRODUCING UARBON BLACK Original Filed March 31, 1933 5 Sheets-Shegt 4 INVENTO JOHN J. JAKos'fi; BY VICIOR. F. Hmson,

ATTORNEY F 1939- J. .l. JAKOSKY ET Al. $1,148,350

METHOD FOR PRODUCING UARBON BLACK Original Filed March 31, 1933 5 Sheets-Sheet 5' Patented Feb. 21, 1939 METHOD FOR PRODUCING CARBON BLACK John J. Jakosky, Los Angeles, Calif., and Victor F. Hanson, Niagara Falls, N. Y., assignors to Electroblacks, Inc., Culver City, Calif., a corporatlbn of Nevada Original application March 31, 1933, Serial No. 663,790. Divided and this application October 17, 1935, Serial No. 45,452

V 2 Claims. ((71. 134-60) This invention relates to the "production of carbon-black, and particularlyto methods involving the production of carbon-black in suspension in an organic-or carbon-bearing liquid medium, as forexample by electrothermal dissociation of such a-liquid, and the separation of the carbon-black from such liquid medium, by evaporation. v

This application is a division of ourco-pending application Serial Number 663,790, flied March The invention may be considered as comprising a method of heat-treating a mixture of carbon-black and an organic liquid, such as an oil, to effect a substantially complete separation of liquid and other impurities from the carbonblack and produce a carbon-black having certain characteristic properties which render it especially advantageous for certain purposes, such as 26 rubber compounding. Such method of treatment may be applied either to a mixture of carbonblack and organic liquid obtained by the direct production of carbon black in suspension in such a liquid by electrothermal dissociation or other 25 means, or to a mixture prepared by mixing an impure or inferior carbon-black or lamp-black product with a suitable organic liquid, the principal purpose of the treatment in the latter-case being to alter or improve the properties of the 30 black and obtain a superior grade of carbon-black having more desirable characteristics for certain purposes. 1

According to the methods of production of carbon-black by electrothermal dissociation of carbon-bearing liquids hitherto proposed, par ticularly as exemplified in Jakowsky Patent 1,597,277 and Jakosky Patents 1,673,245 and 1,872,297, the-carbon-black was produced in a liquid medium consisting principally of carbonsubsequently removed by filtration, centrifugal separation, evaporation (following concentration of the carbon-black by settling, filtration or the like), or by extraction with a suitable solvent.

Although various methods of separating carhon-black from oil suspensions have been proposed, it has been found that the only practical and satisfactory method for removal of the last portion of liquid from the carbon-black is by 50 evaporation. The methods heretofore proposedbearing liquid from which the carbon-black was method in .which the necessity for mechanical concentration of the carbon-black-liquid-mixture is eliminated, by so conducting the process that the liquid separation may be effected entirely by evaporation, without requiring the furnishing 5 of a prohibitively large amount of heat for this purpose.

In addition to other disadvantages the abovementioned methods hitherto disclosed for production of aliquid-free carbon-black have been m found unsuited to the production of carbon-blaclr of the most advantageous properties for use in the rubber trade. The extraction method produces a rubber black which possesses the proper physical and chemical characteristics, but this method 15 of separation has not been found economically feasible. Partial separation of the carbon-black from the liquid medium by filtration or centrifugal treatment must necessarily be followed by a more complete separation, such as by evaporation or extraction, and the cost is much higher than in the process of the present invention. Furthermore, it has been found that, when certain type oils are treated for the production of carbonblack, a filtration or centrifuging step prior to evaporation causes a compacting of the carbonblack particles so that, upon ultimate drying of these particles, a carbon-black is produced which is quite diflicultly milled into rubber; a" serious disadvantage as regards the use of the material in rubber compounding.

Removal of the residual liquid by previously proposed methods of direct evaporation from the carbon-black-oil-mixture, or ofevaporation from a concentratedmixture obtained by filtration or centrifugal means, has been found impractical for the production of the higher quality blacks, for the reason that ,the residual carbon-bearing liquid is in part caused to sinter the carbonblack particles together, forming relatively dense coked particles or agglomerates of carbon which cannot be properly dispersed when milled into rubber. It has been fou'ndthat this objectional sintering is apparently due to the relatively long heating period required in previous methods of this type, which results in the formation of certain gums or polymerization products from the residual carbon-bearing liquid or from the vapors thereof. These products, in turn, cause a cementing of the individual carbon-black particles into rather large and. diiiicultly disintegrated agglomerates.

In the methods heretofore proposed for drying a mixture of carbon-black and oil by evaporation,

the drying operation necessarily extends over a considerable period of time. This results in the formation of considerable quantities of gum and resinous materials. The conditions in the drying operation itself favor the formation of such gummy materials due to the relatively high unsaturation of the oil and the high temperatures existing during the drying operation. The amount of gum formed is influenced-by the rate of vaporization as well as other conditions existing during the drying operation. The longer the drying time, the greater is the quantity of gummy materials formed. The greater the unsaturation of the oil and the higher its end point, the greater has been the amount of gum formed in the final black produced. It hasbeen found that this percentage 'of gum can be greatly reduced by making the drying time as short as possible. Another factor which influences the percentage of gum formed may be termed the surface or contact effect. It has been found that gum formation is increased when an unsaturated oil is evaporated to dryness in contact with the heated walls of a metal container and/or with large masses of carbon-black at high temperature. Tests have shown that this percentage of gum can, therefore, be reduced by employing two conditions during the drying operation: (1) a rapid or instantaneous evaporation of a relatively large proportion of the oil from the black; and (2) minimizing the contact of the oil being evaporated, or the liberated vapors, with the retort walls or the partially dried black.

An important object of this invention, therefore, is to provide a method for effecting substantially complete separation of oil or organic liquid from carbon-black, by evaporation, under such conditions as to cause extremely rapid or "fiash evaporation of a considerable portion of such liquid and to also minimize contact of the liquid or the vapors thereof with heated walls or with heated masses or particles of carbon-black, and thus minimize the formation of gums or other polymerization products during such operation.

Furthermore, the presence of oxygen during the drying operation also tends to increase the formation of gums or other objectionable polymerization products. In addition, the presence of oxygen-bearing gases during the drying operation and the subsequent cooling of the black is objectionable due to the tendency of the carbonblack to take up or adsorb such oxygen or oxygen-bearing gases, which detract from the properties of the black, particularly when compounded with rubber, it having been found that such adsorbed oxygen or oxygen-bearing gases tend to cause deterioration of rubber.

Consequently a further object of the invention is to provide a complete process for production of carbon-black by electrothermal dissociation, and subsequent removal of liquid and cooling of the dried black, under conditions of substantial exclusion of oxygen.

A further important object of the. present invention is to produce a carbon-black of admirable characteristics for use as a filler, particularly in rubber compounding, by a method involving separation of the carbon-black from hydrocarbon liquid and other undesirable constituents in such manner that the advantageous properties of such black with respect to such use thereof are preserved.

A further important object of the present invention is to provide a method for the production of carbon-black characterized by its substantial freedom from adsorbed or condensed gums, cementing materials, coking agents and hydro-carbons, and by its ease of proper dispersion by milling into rubber.

Other objects of the invention will be apparent in the following description, or will be specifically pointed out therein.

In one method of practicing the present invention, a. carbon-bearing liquid is subjected to electrothermal dissociation under superatmospheric temperature and pressure conditions, to cause dissociation of a portion of said liquid to form carbon in highly comminuted state dispersed in the remaining liquid, and the resulting mixture or suspension of carbon in the remaining liquid is then subjected to a rapid evaporating operation at reduced pressure, to separate said remaining liquid from said carbon by evaporation thereof at a pressure lower than that maintained during such dissociation, and preferably at a pressure not in excess of atmospheric, to produce substantially pure, liquid-free carbon in the physical state commonly referred to as carbon-black. The above-mentioned dissociation may be carried out by maintaining an electric arc discharge between electrodes submerged within a body of such liquid, and the evaporation of the remaining liquid from the carbon is preferably effected largely or wholly by flash-evaporation obtained by discharge of the mixture of carbon and liquid, while still at a high temperature, from the superatmospheric pressure under which the dissociation is conducted, into a drying chamber maintained at relatively low pressure. This flashevaporation step may be followed by a further heating operation for the purpose of removing residual volatiles or liquids, if any, which may be present in said carbon-black after such flashevaporation.

The dissociation step is preferably conducted under such temperature and pressure conditions as to provide for flash-evaporation of substantially all or a major portion of the residual carbon-bearing liquid from said carbon-black by the agency of the sensible heat of said liquid and said black, whereby a relatively small amount of additional heat isrequired for complete drying of said black following said flash-evaporation step.

Another important feature of the invention is that the dissociation of the carbon-bearing liquid may be carried out under conditions which allow for maintenance of high concentration of carbonblack in the liquid, which has hitherto been unattainable without excessive heat losses. According to this invention the electrothermal dissociation is preferably continued until a concentration of between 5 and per cent of carbon-black by weight is obtained in the carbon-black-liquidmixture, and the mixture is maintained during such dissociation under a sufficiently high pressure to permit substantially all of the heat delivered to the liquid by the electrothermal dissociation means to be retained in the liquid without causing excessive vaporization thereof in spite of the relatively low throughput of the liquid which is necessary to provide this relatively high concentration, and the heat thus retained in the oil is subsequently utilized in the evaporation of the remaining liquid from the mixture. After completion of the drying and heat treatment of the carbon-black, said black is subjected to a cooling operation, preferably in an enclosed chamber.

Another important feature of the invention is that the heattreatment of the black following flash-evaporation is carried out under conditions of progressively increasing temperature, and the vapors evolved during the flash evaporation and during'said heating operation are removed from the carbon-black in such manner as to prevent contact of said vapors with carbon-black. particles, or with heated wall surfaces, which are at a higher temperature than said vapors. This re sult may be attained, for example, by passing the carbon-black, following flash-evaporation, longl tudinally through a drying chamber of progres sively increasing temperature, and withdrawing evolved vapors longitudinally of said chamber in a direction opposite to the direction of travel of the carbon-black. If desired, the vapors may be positively removed from the chamber adjacent the position of evolution thereof, as by means of a perforated vapor outlet pipe extending longitudinally within the drying chamber.

The process of the present invention is preferably carried out under conditions which provide for substantially complete exclusion of oxygen, this being accomplished by maintaining the liquid undergoing dissociation, as well as the carbonblack in all the stages of production, in an atmosphere consisting principally of gases evolved by the electrothermal dissociation, or other oxygenfree gases. Such oxygen-free gases will, be referred to hereinafter as inert gases. It has fur ther been found desirable in some cases to conduct the drying and cooling steps of the carbonblack production cycle in the presence of a counter-current stream of such an inert gas, whereby removal of volatiles from the carbon-black may be facilitated by a reduction of the partial pressure of such volatiles during the drying step and the carbon-black may be protected from contact by oxygen-containing gases during the cooling step.

The cooling procedure may, if desired, include the introduction of a. suitable treating agent in vaporform to the cooling black so that said black is caused to cool in the presence of such an agent, as and for the purpose hereinafter set forth.

The above-described method is preferably carried out continuously, by continuously supplying a carbon-bearing liquid to the dissociation chamber and continuously removing the carbon-blackliquid-mixture therefrom and subjecting the same to flash-evaporation followed by heating and cooling, as above-described, and the gaseous dissociation products formed by the dissociation reaction (which may comprise hydrogen, methane, acetylene or the like) are preferably also continuously withdrawn from the chamber and passed in heat exchanging and scrubbing relation to thein-coming liquid, in such manner that the sensible heat of such gaseous products is utilized in heating such liquid, and in such manner that'any carbon-black or condensible carbon-bearing liquid products carried by such gaseous products will be caused to enter the in-coming liquid stream and be thus returned to the dissociation chamber.

The carbon-black produced by the gases to be absorbed in the entering oil stream and herein described is characterized by certain physical properties, such'carbon-black being preferably obtained in the form of small loosely bonded aggregates of carbon particles which may be readily crushed or milled into an impalpable powder, but which are possessed of suflicient physical strength to allow reasonable handling thereof without excessive flylng" or floating of' the finer particles. The carbon-black obtained by practice of the present invention is particularly characterized by a definite vesicular or "honey-comb structure of the individual aggregates above referred to.

The accompanying drawings illustrate one form of apparatus in which the method of the present invention may be carried out, and referring thereto:

Fig. l is a diagrammatic representation of one form of apparatus which may be used for practice of the complete invention; 7 i

Fig. 2 is a vertical section, partly in elevation, of the dissociation chamber and dryer-feed portions of the apparatus, on an enlarged scale;

Fig. 3 is a sectional detail of the form of carhon-black treater or dissociation chamber shown in Fig. 2, taken on line 3-3 therein;

Fig. 4 is a sectional detail of an alternative form of feeding device for the dryer;

Fig. 5 is a partly sectional side elevation of the drying apparatus shown diagrammatically in Fig. 1;

Fig. 6 is a transverse section thereof, taken on line 6-6 in Fig. 5;

Fig. 7 is an enlarged sectional detail of the means connecting together the upper and lower sections of the dryer;

Fig. 8 is a partly sectional elevation of an alternative form of apparatus adapted for carrying out the flash-evaporation step of the present invention;

Figs. 9 and 10 are sectional details thereof, taken on lines 9--9 and |0-l0, respectively, in Fig. 8;

Fig. 11 is a partly sectional elevation of an alternative form of dryer means, in which the drying operation is divided into three separate stages;

Fig. 12 is an enlarged sectional detail of the upper end portion of the first stage of the dryer shown in Fig, 11;

Fig. 13 is a transverse view taken on line |3-I3 in Fig. 12;

Fig. 14 is an enlarged longitudinal section 01' a. portion of the dryer shown in Fig. 11, showing a form of feeding means which may be used intermediate the several stages.

Fig. 1 shows a schematic layout of the various elements of apparatus which may be used in the practice of the method of the present invention, and pertains particularly to the manner in which the various elements are correlated to obtain the desired heat economies of operation; referring thereto; is a storage receptacle for the carbonbearing liquid (such a liquid being hereinafter referred to as oll), connected by a conduit to a scrubber and heat exchanger 2 which is in turn connected to an electrothermal dissociation chamber 3 by means of an oil conduit 3a and a vapor conduit 3b. Said scrubber is adapted to receive gases from the chamber 3 through the conduit 31) and heat the oil supplied to said chamber from the storage receptacle I, so that most effective utilization of the thermal energy in these gases may be had and at the same time cause the principal proportion of condensible vapors in said returned to the dissociation chamber. Any carhon-black carried over from the dissociation chamber-by the gas stream will also be removed from such gases by contact with the oil stream in said scrubber and returned to said chamber. The cooled and substantially clean gas is preferably conducted to a suitable gas-holder or gasometer 4 through a suitable conduit la.

Within the dissociation chamber 3 the oil-is subjected to electrothermal dissociation which results in the formation of carbon-black within theoiLandthemixtureofcarhm-blackandoil (hereinafter referred to as Carbon-black-oilmixture, and abbreviated CBOM") is passed under pressure and at an elevated temperature cooling zone or. section 82 into a suitable receiv-' ing hopper I. Suitable means such as a screw conveyor in may be provided i'or removal of the the condenser I i.

cooler carbon-black from the hopper l to suitable storage means I, from which it may be withdrawn by conveying meanslb and delivered to suitable packaging means, if desired. The present invention also contemplates subjecting the cooling carbon-black to the action of a suitable treating agent, subsequently described, and provision is made, as at l, for the introduction of such agent. A-suitable inert gas may also be introduced at I to facilitate removal of the volatiles from the carbon-black.

The vapors resulting from the flash-evaporation of the CBOM and the subsequent drying of the carbon-black are withdrawn from the kiln adjacent the inlet end thereof as at .8, and are passed to a cooling condenser I I, wherein the condensible portions of such vapors are separated and returned to the oil supply means, for example through the conduit l2 to the line In, and the non-condensible gases are passed through conduit lb to' the gasometer. In some cases, the liquid collected in condenser ll may contain a liquid other than the condensed oil vapors: for example, if a treating agent is introduced at 2 which is immiscible with the condenser carbonbearing liquid and in such cases, a suitable separator I! may be connected to conduit l2, for example, as shown, to provide for separation of any such immiscible liquid. In the event that it is considered desirable to operate the dryer I at a sub-atmospheric pressure, a suitable pump it may be connected in the vapor line coming from It may also be found desirable to provide a'suitable pump in the conduit l2, for example as shown at I24, to facilitate return of the condensed vapors from condenser Ii or separator I: to the oil line 211, this pump being of particular advantase when the condenser Ii is operated at a sub-atmospheric pressure.

In order to take advantage of the latent heat of the vapors discharged from the dryer, this thermal energy may be utilized to heat the oil supplied to the dissociation chamber. For this purpose, the vapors from the dryer may be passed directly into the scrubber and heat-exchanger 2, as for example bymeans of a conduit 90 leading from the conduit 9 to the conduit lb.

A suitable pump 9b is preferably; provided in the conduit 90 to facilitate transfer of the vapors from the conduit 9 to the conduit 3b.

It may also be found desirable or convenient to provide a pump in the line leading from the oil storage through the heat exchanger to the dissociation chamber, so that oil may be continuously forced into said chamber independent of the pressure maintained therein. This pump may be located in the oil line 2a enteringtheheat exchanger, as at I, orthis pump may be put in theoillineiaadiacentthedissociationchamber 3 if desired.

Flgs.2and3show thedissociationchamber! in more detail. Said apparatus is shown as being of the type shown and described in the pending .application of Jakosky, Serial No. 588.146 andits axis, and a relatively rotatable electrode hold er 23 mounted on a rotatable shaft 24 and having one or more radial arms 23a each carrying a rod-shaped electrode 25 of relatively small crosssection disposed above the corresponding electrode surface 22a and inclined rearwardly with respect to the direction of travel of said electrode at a suitable trailing angle. The electrodes 22 and 25 may be formed of' any suitable conducting material; for example, such electrodes may advantageously consist of carbon and may be manufactured in the same general manner as other carbon electrodes commonly employed for maintaining electric arcs. Power supply to the respective electrodes may comprise suitable connection to the several electrodes whereby electrical energy at the desired potential may be supplied thereto after the manner shown. 'It has been found convenient to insulate the ring electrodes 22 from the casing 2| ahd connect these electrodes each to a separate phase of a threephase power supply system, which may comprise a suitable transformer T, through suitable reactances R and R or the like, while connecting the rotating electrodes to ground as at G through the common shalt upon which they are mounted, through the casing 2|, as shown in Fig. 2.

It will be understood that suitable driving means, forexample, a variable speed motor 244, are provided whereby rotation of the shaft 24 may be had, and that adjustment means such as is indicated at 24b, are provided for determining, maintaining and adjusting the separation of the rotatable electrodes from the fixed electrodes through longitudinal movement of the shaft 24. The above mentioned means, for the purpose of the present description, may be substantially as shown and described in the above-referred-to pending application, Serial No. 588,146.

At the concentrations of carbon-black contemplated in the present invention, it is dimcult to accurately govern by means of a valve the feed of the CBOM from the dissociation apparatus to the drying apparatus. Means are therefore provided for properly controlling this feed, and the form of feed-control means shown herein may comprise one or more montejus devices such as indicated at 26 and 21, provided at their lower ,end'sfwith connectidn as at 2611 and 21a to the dissociation chamber 3, and at their upper ends with pressure fluid connections 28b and 21b. The above-mentioned connections are provided with suitable valves indicated by prime marks on the respective reference numerals, as at 26a, etc. A line 28 connected to the bottom of both of the montejus devices through valved connections 28a and Zlb leads to the inlet end of the dryer 5.

The mountains devices it and it may be pro"- vided with valved vents its and lie at their up per ends.

tilhen it is desired to feed ilhfl lill into the dryer, one at the monteius devices, ifor example lid, is tilled with ChiUll/i irons the dissociation charuher lay opening the valve lilo, the valves iiiti, liter, and the closed. its the pressure in the dissociation chamber forces the Cldtllid into the medicine, the vent items-:7 be crashed slightly so as to allow the montejus to hill, and the vent valve idle and valve the then closed. The valve tile is then opened to the desired degree to admit a suitable pressure fluid, such as a compressed hydrocarhon gas, to the montejus it, and the valve the. opened to allow the 0180M to be forced out through the line it to the dryer. While the montejus it is being emptied into the dryer, the montejus til may be filled as above described, and the respective monteius-detdces may be al ternately operated, so that a substantially con tinuous withdrawal or. ChOli/l item the dissoci ation chamber t and a substantially continuous supply of CBOM to the dryer is maintained.

The dryer it may comprise an elongated tube inclined downwardly from the inlet to the outlet end, provided with external heating means tor the upper or inlet end portion, said heating means being preferably so disposed as to provide a cone of continuously increasing temperature downwardly from the inlet end to the lower end of said portion. The'dryer, asshown in Figs. 5 to said lower section,

lhtTdp-ipcrsewtli is provided with heating '7, may comprim anupper or heating section 3i and slower or cooling section 32. The upper section 3! is preferably of greater cross-sectional area than the lower section 32, so that-the carbonblack in descending through the upper section will occupy a relatively small proportion of the. cross-sectional area or said section, whereby .minimum contact of the released vapors with said black is obtained, while causing the carbon-black to occupy a relatively large proportion or the cross-sectional area of the lower section I2, thereby assuring better contact between the material and the dryer walls to facilitatetransfer- 01 heat from the black to said walls, and better contact between the black and the treating vapor or gas which may be passed upwardly through as subsequently described.

means which may mprise a burner 33 directed into a fire-430x 34 pr oylfiwvith a heatin chamber or flue 35 built around the ction 3| and having a stack 36 at the upper end thereoil- Th1 construction provides for maintaining a downwardly increasing temperature in the heating section 3| in such manner that the carbon-black descendlng through said section is exposed to continuously increasing temperature during its downward passage from the inlet end to the lower end of said section. The dryer may be rotatably mounted on suitable bearings 31a, 31b

and 310, which may rest on suitable supports 38; Referring particularly to Figs. 2 and 4, the upper end of the upper section ii is provided with a tubular extension 39, preferably of re-' duced diameter, on which is mounted a sprocket 4| through which the dryer may be rotated by means of a chain 42 and a motor 43. Said extension 39 extends within a fixed housing or vapor outlet chamber 44, provided with a. vapor outlet connection 9 leading to the condenser ii The CBOM supply line 28 is connected to an inlet pipe 46 which extends longitudinally through housing 44 and extension 89, said inlet pipe preferably terminating within the upper end portion oi the dryer section iii in position to discharge the 6150M into said section, preferably toward the sidewalls thereof, as by means ot a noanle shown at The chamber is preter ably also provided with a vapor-tight connection with the tuhular extension as by means at a striding-boa:

The CBOM feeding means shown in ."i ia'. i may, if desired, he used in place of the plain nestle ll, so that a gas relatively inert at the temperatures involved, may he used to atomiae the CBOM into the dryer. .l'his alternative form of teeding means may comprise an. atomizing gas line that extending longitudinally through the housing it and the tubular extension he and provided with a discharge nozzle 5% at its inner end, and a CBOM discharge line the extending within said line the and terminating adjacent said nozzle. This arrangement provides tor introduction oi CBOM into the dryer through the discharge line the simultaneously with the introduction oi atomlzing gas through the noaale iitb, whereby said CBOM is atomized in its introduction to the dryer.

If desired, a super-heated gas may be introduced to the CBOM discharge line 28 at any suitable point for example such as at 280, as shown in Fig. 2. It will be comprehended that any suitable type of gaseous agent may be introduced in this manner, for example, hydrogen, methane, or other suitable gas. such as that produced during the dissociation of the oil and consisting in general of a mixture of hydrogen and gaseous hydrocarbons. In some. cases, steam may be introduced at this point, although we prefer, in general, to use an oxygen-free gas.

As shown in Fig. 5, the lower end of the dryer may be provided witha suitable hopper 6, to re ceive the dried carbon-black, the hopper being conveniently provided with a clean-out manhole to whereby the black may be removed at intervals, as desired. A suitable form oi packing or stufling-box means 8?; is preferably provided for the hopper, so that escape of gases from the dryer can be prevented. It will be understood that a. suitable continuous discharge means such as is shown at M in Fig, 1 may alternatively be provided for the tinually removing material from said hopper and conveying the same An inlet pipe 8 may be provided, extending upwardly a short distance into the lower section 32 for introduction of a treating agent or inert gas into the drying zone.

At the junction of the sections 3| and 32, where arrange in diameter of the two sections takes mtable means are provided for hopper, ii desired, forv conto a storage receptacle 1.

Fill

causing the dried c i-bomblack to enter the tube 32 in such manner as to prevent a umulation of dried black in contact with the side walls or the heating section at the lower end thereof7'\ 'Such means, as shown in Figs. 5 to '7, may convenlentlycomprise a baille plate flla disposed diametrically across the lower end of the section 3| and two oppositely inclined scoop-plates 3m and 3lb disposed at opposite sides or the plate Ma. The rotation of the dryer (in the direction" indicated by the arrow in Fig. 6) will cause .the scoop-plates to gather such dried black as may fall into the lower portion of the apparatus at the point indicated by the arrow Z and lift the same through a portion of a revolution of the dryer and then cause the black to pass by gravity into the upper .end of section 32.

said housing and said bearing member 51 being heat exchanger 2,

the liquid body super-atmospheric temperature? secured together frictionally by means of packing material 54 which is kept under compression by means of a flange 55 bolted to-the flange 530, so that upon rotation of the section 3| by means of the motor 43, the frictional engagement of the packing material between the housing 53 and the bearing member 52 will cause a rotation of the section 32. A sufl'icient amount of play is left between the section 32 and the end of the section 3i as at 56, and between the flange 55 and the section 32, as at 55a, so as to accommodate any misalignment of the one section with respect to the other section. The bearing 31a at the lower end of the section H'Jnay be of such construction as to take up any thrust in said section, and preserve the longitudinal position of said section, while the upper bearing 31b on section 32 and the bearing 310 on section 3| may be allowed to float so that longitudinal expansion of the dryer will occasion no bearing difllcult'y. As the dryer expands the tubular extension .38 may slilde with respect to the housing 44, through the stuflingbox I.

In one method of practicing the present invention, a carbon-bearing liquid such as, for exampl kerosene, Edeleanu extract, or other suitable quid (any such liquid being generally referred to herein as an "011"), is placed in the storage receptacle i and a supply of this oil is conveyed to the dissoctation chamber 3 through the heat exchanger 2. With the electrodes 22 and 25 properly energized, an electric arc will lene, methane, hydrogen, and other gases, which are passed from the chamber to and through the and thence to the gasometer l for storage.

The electric arcs within the dissociation chamber 3 evolve considerable heat, and the heat thus evolved is utilized to increase the temperature of within the chamber to a suitable According to the preferred embogmen of the present invention, the yore of carbon-black and dissociable liquid 1B aintained under a super-atmospheric i pre ssure within the dissociation chamber, sumclent to prevent boiling of the liquid at the temperature'of operation, which temperature is preferably about equal to or in excess of the boiling point of the heaviest fractions of the liquid, at the pressure at which the subsequent flashevaporation is conducted.

When a dissociable liquid such as kerosene is used for production of carbon-black according 'to the present invention it has been found practical to maintain a gauge pressure of lbs. per sq. in. on the dissociation chamber, which pressure will allow of an average temperature of in the neighborhood of 500 F. to be attained by the CBOM within the treater without excessive gasiflcation or vaporization of the dissociable liquid.

The dissociation is continued until a suitable concentration of carbon-black is realized in the mixture, the upper limit of this concentration being limited principally by the fluidity of the mixture. In general, the liquid is preferably caused to remain in the dissociation apparatus until the concentration of carbon-black therein has reached approximately the maximum value consistent with the above mentioned limitations. When kerosene is used as the dissociable liquid, this concentration may conveniently reach approximately 13% carbon-black under the tem perature and pressure conditions above outlined, while concentration above this amount has been found to cause surface leakage on insulators within the dissociation chamber.

When a suitable concentration of carbonblaclr has been attained in the mixture within the dissociation chamber, this mixture may withdrawn from the treater and introduced to one of the montejus devices 26 or 2?, and fresh oil introduced to the treater, it being understood that the rate of withdrawal of the CBOM and the rate of supply of fresh liquid to the treater may be so balanced as to maintain a substantially continuous flow of liquid to and CBOM from this trcater.

Referring to Fig. 2, when one montejus is filled with CBOM to the desired extent, the valves 23a, 26b, 26c, 21a, 21b, 210, 28a and 28!) are properly set so as to obtain delivery of CBOM from the montejus' to the dryer, suitable fluid pressure being applied to the montejus so as to force the CBOM through the inlet line 28. It will be understood that the CBOM is preferably maintained under the above mentioned superatmospheric temperature and pressure conditions up to the moment of discharge thereof into the dryer section 3| and the monteius devices and the necessary supply pipes'may be provided with suitable insulation for this purpose. When the CBOM is discharged into the dryer, which is maintained at a relatively low pressure preferably not in excess of atmospheric, the mixture will "flash", causing a vaporization of the major portion of the volatile matter in said mixture.

It will be comprehended that, dependent upon the concentration of carbon-black and the temperature and pressure at which the mixture is flashed", the degree of vaporization of the volatile constituents of said mixture may be controlled within rather wide limits. It has been found disadvantageous to cause a complete vaporization of said constituents in the flashing operation for the reason that the carbon-black thus obtained is in the form of a very fine. almost impalpable powder, which is not only difllcult to collect but is not preferred by the rubber trade inasmuch as it is very disagreeable tohandle. In order to produce a carbon-black, therefore, which is properly dried yet in suitable physical condition, the present invention particularly c0ntemplates flashing the CBOM under such temperature and pressure conditions and at such carbon-black concentration that the flash evaporation thereof results in the formation of lumps or loosely-bound agglomerates of carbon-black particles and a very small proportion of dust or substantially none at all. According to the preferred method of drying the CBOM, these' loosely bound agglomerates have a honey-comb" or vesicular appearance and structure similar to that of lava or other material which has solidified u ascents while evolving gases or which contained considerable uuantitiesoi gas duringsolidiflcation. this honey-comb structure of the dried material allows it to be broken down with very slight mechanical pressure and this feature is of particular advantage in providing for better incorporation and dispersion or the material in rubber. The size of these agglomerates is preferably maintained on the order of a few millimeters in diameter, ior example from 0.75 to 10 mm. in diameter.

When the mixture is flashed under such conditions as to produce lumps of the size and type above described it has been found desirable to subject the same to a further drying operation to remove the residual liquid and gaseous material. According to the preferred form of the invention, therefore, the CBOM produced as above outlined is flashed into a suitable heating cone under such conditions as to produce the above described lumps and therein and thereafter on posed to sulhcient additional heating to com pietely remove the maiorproportion of volatiles thereirom.

When a dryer oi the type herein disclosed is used, the CBOM is flashed into the upper section ill and is allowed to pass downwardly through this section upon rotation thereof after moved downwardly through the dryer and isgradually brought to maximum temperature, while the gaseous products are driven upwardly post the descending black in such manner that these gases are caused to contact carbon-black and surfaces which are at a lower temperature than that of the gases whereby decomposition of these gases by. such contact is minimized to a a great degree, minimizing formation of the aforementioned condensation or polymerization products which cause a sintering of the material.

After passing through the dryer section 3| the black is led into the dryer section 32 by means of the arrangement shown inFigs. 6 and 'l and is progressively cooled during its passage through said section 32, and then mscharged into the hopper b from which it may be withdrawn to storage or packaging as desired.

The CBOM may be mixed with other materials before introduction into the dryer system, 11 desired, for example the CBOM may be flashed into the dryer by atomization thereof with a suitable atomizing gas, an arrangement such 1 as shown in Fig. 4 being used for this purpose. This arrangement obtains a betterevaporation of the liquid constituents of the CBOM, particularly in lowerina the partial pressure or such constituents.

addition to assisting the evaporation, the presence of such can appears to be advantageous in preventing undesirable coking at the CBOM discharge.

' subsequent-heating may be carried out under, such conditions as to maintain a reduced partial pressure oi the said volatile constituentsgluring theevaporating steps, which condition may be obtained by maintaining a subatmo'spheric pres- In addition to the above described means for assisting the evaporation of the liquid constituents from the CBOM, the flash-evaporation and is provided was a sure within the dryer or by passing a suitable inertas through said dryer by introduction oi such a gas at t, and establishing a stream of such gas through and over the drying black.

Instead oi, or in coniunction with the introduction oi an inert ges for the purpose above outlined, the residual volatile constituents of the carbon-blunt: may be replaced by a material the presence or which is of particular benefit in connection with the use to which the black is to be agent with the blasts and in this manner carhonrblaclr productoi highly advantageous r characteristics with respect to a particular use may be obtained. 1 i

it will be understood that whenever an inert material is introduced with the neon into the dryer, or into the dryer through the inlet the principal proportion oi such material will be re- .moved from the dryer through the vapor outlet t5 and will pass tothe condenser It with the vapors liberated from thecarbon-black or CEOM.

Any treating agent such as pine-tar oil, stearic acid, or the like, which has been introduced to I caused to enter the oil stream as above described.

The form or apparatus shown in Figs. 8 to 10 is adapted to provide for a concentration of the CBOM obtained in the dissociation chamber 3 in a combined flash-evaporating and filtering step. The filter portion of this form of device is a modification of a continuous filter" such as that shown and described in reissue patent to J. T. Shimmin No. 18,597, in which a'plurality oi filter surfaces are arranged to receive spray- 'ced CBOM and obtain further concentration by filtration. Referring to the above-mentioned figures, the numeral til indicates a filter housing rotatably mounted as at ti and it on suitable supporting means and provided with H rotating driving means t3; the filter housing lit plurality oi filter sections it disposed circumferentially around the inner periphery of said housing and each provided with a suitable supporting structure such as a screen 65 carryinga filter medium such as a woven wire cloth filter surfaceifi. Each oi the filter sections 64 is provided with connections t'l leading from the space behind the filter support 65 and connecting to a conduit 63. The several conduits t8, the number of which corresponds to the number of filter sections M, are brought readily inwardly of the filter housing W and lead into an axially projecting housing portion the and thence longitudinally or the apparatus to and through a manifold plate 89, which forms an end plate for the housing portion Ella. A valve plate H1 is provided adjacent the plate'69 and a clp member 60!) is provided on the end of the housing portion 69!; adapted to hold the valve plate it in position with respect to the plate 69. Thevalve. plate is to register with the open ends of the pipes 68 and connections H and M are provided extending through the cap member 6012 in communiprovided with valve openings Illa and mo adapted cation with the valve openings 10a and Nb, respectively. Connection II 'is preferably connested to suitablemeans adapted to provide a liquid suction, and the connection 12 is connected means adapted to provide a vapor suction. The cap member III: is preferably so disposed on the housing section III: asv to provide a gastlght seal therewith.

The CBOM feed line 15 is brought into the filter through the cap member IIb, being provided with a suitable stufiing-box as shown at 16, and is provided within the housing II with a radially extending portion "a having a longitudinally extending portion lib disposed at a suitable distance radially inwardly of the filter sections II,

said section lib being provided with a plurality of suitable discharge nozzles 15c directed toward the filter surface of said filter sections II. The CBOM is delivered from the nozzles 150 under a suitable superatmospheric pressure and is sprayed or flashed downwardly onto. the filter surfaces II of the adjacent filter section II. As these filter sections pass the nozzles 15 a suction is applied thereto through the conduits II which are in communication with the connection II through the valve openings lIa and this suction will obtain a removal of a portion of the unfiashed liquid content of the CBOM, which is drawn off through the connection II and may be returned sociatlon chamber I. After the filter sections have passed through a suitable portion of a revolution of the housing II, for example through an are such as indicated at P1 in Fig. 9, the conduits II are disconnected from the suction line II and are connected to the suction-line I! through the valve opening IIb, and the portion of the revolutlon of the filter indicated at F: is utilized in the removal of gas from the interior ofthe filter II so as to maintain the same under sufilclently low pressure to provide the desired flash-evaporation. This gas may consist of fixed gases resulting from the dissociation step and vaporized constituents of the CBOM. The above described filtering operation results in the formation of a layer of carhon-black containing a materially low percentage of liquid constituents, and this layer is removed from the filter surface as by means of a stripper or scraper I1 and caused to fall into a hopper II, directed into a screw conveyor II and removed from the filter into a conduit II which is directed intctheopenupper end of a dryer, which may,

if desired, be of the same general type as that shown at I in Fig.1 and Fig. 5. A suitable driving means is provided for the screw conveyor II, such as shown at II, and a suitable vapor duct II is provided for the upper end of the dryer II, correspending to the vapor duct I shown in Fig. 2, suitable stumng box means being provided as at II to obtain proper sealing of the rotating upper end of the dryer tube with the vapor duct.

It will be understood that suitable sealing means are provided for sealing the screw-conveyor to the-filter,'so that atmospheric air is not drawn into said filter, and mixed with the hydrogen and other gases therein. The filter housing II may be provided with an end plate II, and the housing carrying the portions of the screw-conveyor whichare exterior of the filter may be provided with stufilng-box means is" at the point of passing through-said end plate. to effect such sealing. It will be further understood that the entire filter housing II rotates with respect to the conveyor II, and said conveyor rotatably through the end plate II? and may be 'rotatably tothedis supported at the other end of said housing as at Ma.

The form of dryer shown in Figs. 11 to 1 is a modification of the form of dryer shown at 5 in Figs. 1 and 5, and comprises, essentially, a relatively low-temperature heating stage designated as stage I, a relatively high-temperature heating stage designated as stage H, and a cooling stage designated as stage 111. Stage I of the dryer may comprise an inclined tube 86 rotatably mounted in a heating chamber I1 and provided with CBOM feeding means at the upper end thereof and carhon-black discharging means at the lower end thereof. The CBOM feeding means may comprise .a conduit 88 extending downwardly into said tube through a fixed housing II mounted on the upperend of said tube in such manner as to provide a vapor seal therewith and at the same time permit rotation of the tube II. At a suitable point within the tube as, the conduit as may terminate in a CBOM discharge nozzle 88a, such point being preferably adjacent the upper end of the heating chamber II. The lower end of the tube 86 may open into a suitable hopper II in position to discharge carbon-black thereinto, suitable vapor-sealing means being provided at the point of entrance of said tube to said hopper, such as a stufiing box I2.

The hopper II is adapted to deliver carbonblack downwardly into the stage II, which may comprise a'tube II, provided at one end with a portion II of reduced diameter, and the hopper I I may be provided with a spout II opening into the portion II. The tube II is provided with a screwconveyor II having driving means I1 and adapted to carry the carbon-black from the portion II through the length of the tube II to the other end thereof, at which point a conduit II leading to stage III is disposed. Stage 111 may comprise a tube II provided with a reduced portion III after the manner of the portion II of the tube II, and the conduit II is so disposed as to open into said portion III. The tube II is provided with a screw-conveyor after the manner of the tube 93, Fig. 14 showing the construction of this 'conveyor in the vicinity of the reduced portion III in greater detail. The screw-conveyor may comprise a portion III of large diameter fitting within the tube II and provided with an extension III of reduced diameter and decreased pitch fitting within the portion IIL The particular arrangement shown is for the purpose of providing a relatively slow feed of carbon-black from the conduit II so that the reduced portion III may be maintained substantially full of such carbonblack while providing relatively faster feed of such carbon-black through the tube II, so that such black will only partially fill the cross-section of said tube. The above described feeding arrangement is also preferably used between the means which may be provided for obtaining the desired feeding of the carbon-black, but it is an advantageous construction in view of the fact that to some extent a vapor seal is preferably provided between the several stages, for purposes herein after described, and the above construction will- Q wardly thereof through a. conduit I connected through a heater I08 disposed in the fire-box I01 of the heating chamber 81 to a conduit Hi8 communicating with the discharge end of the iii tube 88. A conduit I08 leads from adjacent the inlet end of the tube 83 to storage, or other disposition. A by-pass conduit I I0 is connected into the line I05 at a suitable point. and is led into the lower or discharge end of the tube 86, said conduit extending through the hopper 9| and upwarly into said tube 86 to adjacent the position of the upper end of the heating chamber 81 and there terminates in a closed end, for example as shown at 0b in Fig. 12. The portion oi the conduit iiii lying within the tube 86 is provided with a series oi perforations i iiia adapted tor discharge of vapor into said tube. Means are provided for removal oi gas from the tube iii, and such means may comprise a conduit iii having closed lower end its eutending iroru adjacent the lower end at the tube upwardly through said tube along side the conduit tilt, as shown in iii ior example, and outwardly through the tired housing This conduit may be connected to any suitable storage means, such as the gasometer i, as desired. The'portion oi the conduit lying within the tube it is provided with a series of perforations iii extending from adjacent the closed lower end upwardly to a point preferably somewhat above the point of C'BOM discharge. The proportional dimensions of the conduits H0 and ill with respect to the diameter of the tube 88 is preferably such as to allow sufilcient room for the carbon-black to descend through said tube. If desired, the two conduits H0 and Ill may be disposed upwardly oi the axial line 01 the tube 88 rather than axially of said tube. The two conduits are preferably provided with guard or badie means such as a plate till iii disposed over said conduits in such manner as to prevent accumulation oi carbon -blaclr thereon.

in the operation oi the iornr oi dryer above described, the tube i8 is externally heated by heat delivered from the fire box iii, provided with a burner or the like ii i. The heated gases irorhthe fire-box are directed to the lower end of the tube 86, as by means of a duct i 01a, and

are passed in contact with said tube upwardly toward the inlet end thereof through the heating chamber 81, and are discharged adjacent the upper end of said heating chamber through a suitable flue ii 5. The particular heating arrangement shown herein is for the purpose of providing means for progressively increased heating of the tube 86 downwardly from the inlet to the discharge end thereof.

Rotation of the tube 8% is obtained by suitable driving means, for example such as is shown at ti, it and it in Fig. 2 in connection with the dryer 5, and CBOM is supplied through the conduit tit and discharged into the heated and rotating tube to at the nozzle tile. The CEOt/i is flash-discharged into the tube and the carbonblacir is gravitated downwardly through the tube to the discharge end due to the downward inclination and rotation of said tube. The carbon black is discharged from the tube 86 into the hopper 8i and falls through the conduit 95 into the portion 84 of the tube 83, is carried through said tube 88 by the action of the conveyor 86 and fed into and carried through the tube 88 in the same manner as in the case of tube 83. A suitable cooling gas or vapor, such as the gas resulting from the dissociation chamber, is passed at a relatively low temperature into the discharge end of the tube 88 through the conduit I04 and is passed through the tube 88 in counter-current contact with the hot carbon-black. In this contact, the gas is materially heated and the carbonblack materially cooled; the cooled carbon-black being discharged from the tube 88 into a suitable hopper H5, from which it may be removed as desired by means or a conveyor H6 to suitable packaging means, not shown.

The gas which is passed through the tube 88 in heat-interchanging relation to the hot carbonblack, is withdrawn from said tube through the conduit M5 and a portion thereof is led through the heater i06 and thence through conduit i08 to the discharge end of the tube it, and a fur-- ther portion or said gas is passed through conduit iii into the tube lit, suitable valve means being provided as itiiu and iiiiib in the respec tive conduits iidii and iii whereby the propor 'tionai amounts oil such gas are delivered to the desired portions or the apparatus. The portion oi the gas passed through the heater itt isheated to a relatively high temperature and is introduced into the discharge end or the tube 8t and passed therethrough in heating contact with the carbon-black present therein, after which said gas may be delivered through conduit M8 to storage or other disposition. The portion of the gas passed into the tube 88 obtains a reduction of the partial pressure of the volatiles released from the carbon-black undergoing heating in said tube, and is removed through the conduit ill to storage or the like. The gas and vapors withdrawn from both drying tubes 86 and 88 may be introduced to the conduit 8b (Fig. 1) leading from the dissociation chamber 8, if desired, after the manner oi the conduit to leading from the dryer ii, whereby condensible vapors may be recovered therefrom and the heat econornies described in connection with the first-described iorrn oi apparatus may he realised.

The flash-discharged carbon-black is subiected to heat applied errteriorly of the tube t8 whereby the temperature of said black is gradually increased during its downward passage through said tube; and in addition to the heating obtained in the above manner, the heated gas passed into the tube 86 through the conduit ii0 also obtains a degree of heat-interchange with said black and serves particularly to facilitate the removal of the principal proportion of the volatiles from said black by a reduction of the partial pressure thereof. Considerable drying of the black is obtained in the tube 86, but it is preferable that the temperature in this stage be kept somewhat below the maximum temperature required for complete drying, in order to minimize the formation oi polymers or "cementing materials as above described. For example, the temperature oi. the black in stage I'may be irept below about 700 or 8b0 "5k, if desired, so as to provide ior evaporation and removal oi the major portion of the liquid under conditions which preclude heating thereof to an excessively high temperature, and the black may then be raised to a higher temperature in stage II, under conditions which do not favor the formation of such cementing materials. The gas introduced to stage II at the discharge end of the tube 88 may be at a temperature, for example, of from 1000 to 1300 F. and the carbon-black passing through this tube may be thus further heated at an increased temperature and the remaining volatiles bit removed solely through the agency of the counter-current stream of gas. It will be understood that the gas passed in cooling relation with the hot black in stage III and then passed through the heater I06 may be heated to any desired temperature in said heater, this operation cooling the burner gases in the fire-box I01 so that said burner gases will contact the tube 86 t a somewhat lowered temperature.

The drying operation is thus seen to be divided into three distinct stages: in stage I the CBOM is flash-discharged into a heated zone and caused to give up the major portion of its volatiles in the presence of a counter-current stream of gas adapted to lower the partial pressure of such volatiles and assist in the removal thereof; in stage II the carbon-black is further heated and the final portions of volatiles removed therefrom entirely through the agency of a heated gas passed counter-currently therewith; and in stage III, the carbon-black is cooled through the agency of a counter-current stream of gas and the thermal energy of said black utilized in raising the thermal energy of said gas, which is further utilized as above set forth.

The carbon-black is thus constantly maintained in a desired atmosphere, namely that of an inert gas, whereby the desirable characteristics of such carbon-black are preserved. At no time, from the moment of formation of said black until the packaging thereof, is it possible for any deleterious atmosphere, such as air for example, to come into contact with the black, and the cooling of the black in the presence of a desired atmosphere will cause the black to adsorb and become saturated with undeleterious vapors, whereby there is small tendency for subsequent adsorption of any other vapor or gas, such as oxygen, during handling of the black.

The above drying procedure also provides advantageous economies in fuel consumption in addition to the economies set forth in connection with the operation of the dryer 5, particularly in that the sensible heat of the hot carbon-black is utilized in heating the treating gas during the passage thereof through stage III. It will be further appreciated that any desired type of treating agent may be introduced to the black in stage III, such as the above-described pinetar-oil, stearic acid or the like.

In addition to the heat and energy economies made possible by the present process, it will be further appreciated that the present process eliminates the objectionable filtration or solvent-extraction step required by previously disclosed methods. The advantages in this saving are tremendous from the standpoint of labor, and cost of equipment.

We claim:

1. In the recovery of carbon-black from mixtures of carbon-black and carbon-bearing liquid, the steps which comprise: heating such a mixture under superatmospheric pressure; subjecting the heated mixture to flash-evaporation at a lower pressure to cause rapid evaporation of a portion of the liquid therefrom in such manner as to leave suflicient of said liquid associated with the black to bind the particles thereof together in loosely bound agglomerates; separating the vapors so evolved from the carbon-black; and thereafter heating the carbon-black and remaining liquid to cause substantially complete vaporization of the remainder of said liquid.

2. In the recovery of carbon-black from mixtures of carbon-black and carbon-bearing liquid, the steps which comprise; heating such a mixture; subjecting the heated mixture to a flashevaporating operation to cause vaporization of a portion of the liquid contained therein in such manner as to leave suflicient of said liquid associated with the black to bind the particles thereof together in loosely bound agglomerates thereafter; heating the carbon-black and remaining liquid in the presence of a stream of inert gas to cause vaporization and removal of a further portion of such liquid; and then heating the carbonblack to a higher temperature in the presence of an inert gas to substantially completely remove the remainder of said liquid.

JOHN J. JAKOSKY. VICTOR F. HANSON. 

